海宝等离子原理培训课件.pptx

1、等离子切割等离子切割的基本原理的基本原理 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.所有用户在进行金属切割时基本上都在寻求同一个目标:理想的切割效果.以下的因素是鉴定

2、理想切割效果的标准低运营成本低运营成本高切割速度高切割速度无金属热变化无金属热变化垂直的角度垂直的角度优异的公差范围优异的公差范围割缝的尺寸割缝的尺寸稳定的重复性稳定的重复性理想的切割 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.所有的金属切割方式各有其优缺点.基本上,当今在市场上使用的切割方式分为以下几种:机械切割机械切割化学切割化学切割 热切割热切割化学化学/热切割热切割 Copyright,200

3、3 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.化学切割方法是通过化学反应来切断金属.典型的化学切割例子就是火焰切割.使用可燃性气体(丙烷,乙炔.)来产生火焰,在整个化学反应过程中氧气作为辅助气体.注意:在化学切割过程中是气体的化学反应切割金属而不是热能.由于铝和不锈钢与氧气不能很好地产生化学反应,所以这两种常见的金属不能用火焰进行切割.Copyright,2003 Hypertherm,Inc.These materials ca

4、nnot be reproduced in any formwithout the permission of Hypertherm,Inc.例例子子:火焰切割优点优点:良好的切割质量(6MM以上的板材)较低的设备投入资金缺点缺点:较大的热影响区域较低的切割速度只应用于碳钢切割 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.1983年之前,很多的等离子切割都采用热能的方式(即空气等离子).在1983年,美

5、国海别得公司成功的在热能切割方式中引入了氧气.热能与化学反应的有效结合是等离子切割技术的飞越.现在可以利用高温能源和氧气化学反应的特性,有效的把两者的优点结合起来,应用到同一切割过程中.Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.例子例子:氧气激光氧气等离子优点优点:极佳的薄板切割质量切割速度高缺点缺点:有金属化学反应的特性高额的设备投入资金 Copyright,2003 Hypertherm,Inc.

6、These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.物质的结构状态 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.生活中常见的三种物质状态生活中常见的三种物质状态 Copyright,2003 Hypertherm,Inc.These materials cannot be rep

7、roduced in any formwithout the permission of Hypertherm,Inc.固态固态:分子运动速度慢分子运动速度慢多数为晶体状的结构多数为晶体状的结构单一的分子无移动能单一的分子无移动能力力 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.液态液态:分子以中等速度运动分子以中等速度运动单一的分子基本可以自由的运单一的分子基本可以自由的运动动 Copyright,2

8、003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.气态气态:分子以较高的速度运动分子以较高的速度运动单一的分子基本可以自由的移动单一的分子基本可以自由的移动 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.等离子等离子:“物质的第四种状态物质的

9、第四种状态”Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.割具割具平衡的原子是不受外部平衡的原子是不受外部磁场的影响磁场的影响 工件工件 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.割具割具自由电子在电磁场的作用自

10、由电子在电磁场的作用下由负极向正极运动下由负极向正极运动工件工件 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.割具割具正离子在电磁场的作用下由正离子在电磁场的作用下由正极向负性运动正极向负性运动工件工件 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission

11、of Hypertherm,Inc.割具割具在外部能量的作用下平衡的在外部能量的作用下平衡的原子会发生可能性的碰撞原子会发生可能性的碰撞工件工件 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.割具割具原子间相互的碰撞分离出自由的原子间相互的碰撞分离出自由的电子和离子电子和离子,这样周而复始而产生这样周而复始而产生更多的碰撞更多的碰撞工件工件 Copyright,2003 Hypertherm,Inc.Th

12、ese materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.割具割具只要有足够的电能和气体的能只要有足够的电能和气体的能量量,就会形成足够的离子流就会形成足够的离子流工件工件 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.具有高速运动具有高速运动,和和20,000C的高温的高温+-Copyri

13、ght,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.气体离子化后,在气体原子中产生了带负电荷的电子和正电荷的离子.当这一过程形成以后,气体开始具有导电性并且有携带电流的能力，这就形成了等离子体,宇宙中最充足的物质.Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hy

14、pertherm,Inc.引导弧状态无电流流通 在100A电流的切割状态 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.1950s60s70s2000s90s80s1962:Thermal氮气双气流等离子 等离子技术发展过程1957:Linde 专利的氮气等离子工艺60年代中期:在欧洲,俄罗斯,以及日本使用的手持空气等离子1983:Thermal开始发行手持空气等离子1968:海别得高温水射流等离子198

15、5:海别得第一台手持等离子系统1983:HT400 氧气等离子1992:HT2000 氧气长寿命技术HD1070 精细等离子2003:高性能等离子2001:G3 手持系统1999:同轴斜喷技术 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.高空中的闪电 .静电感应 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in a

16、ny formwithout the permission of Hypertherm,Inc.等离子切割系统概述等离子切割系统概述 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.气体 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hyperth

17、erm,Inc.电能,气体与割炬的有效组合气体控制单元气体控制单元 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.等离子切割是利用优化设计的喷嘴,产生经压缩的高温等离子流来熔化,切断被切割的导电金属.(+)(-)等离子割炬工件 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the

18、permission of Hypertherm,Inc.等离子割炬将由电源产生的能量通过等离子流传导到要切割的金属体上 割炬作为一些易损件(如电极,喷嘴等)的载体,并且通过气体或者水对易损件进行冷却.喷嘴和电极压缩并保持等离子射流.Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.机用等离子割炬喷嘴固定帽涡流环电极割炬本体 Copyright,2003 Hypertherm,Inc.These materi

19、als cannot be reproduced in any formwithout the permission of Hypertherm,Inc.手持等离子割炬手持等离子割炬涡流环固定帽保护帽电极活塞喷嘴 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.等离子流存在于旋转的气流中.气体提供了可以被离子化的原子,那些没有被离子化的低温气流包围在离子流的外部,将熔化的金属从割缝中吹掉.Copyright

20、,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.气体流量一般而言气体流量越高,弧越窄In general the higher the gas flow the more constricted the arc.低气体流量导致易损件的过度磨损is a result of consumable wear.Copyright,2003 Hypertherm,Inc.These materials cannot be reprod

21、uced in any formwithout the permission of Hypertherm,Inc.操作步骤操作步骤 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.启动信号加到等离子电源,同时产生开路电压,气体流通.280伏直流_+高频闭关气体流通 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in an

22、y formwithout the permission of Hypertherm,Inc.气体流通稳定后,高频电路工作,割炬内部喷嘴和电极之间的气体离子化后产生高频弧,并形成电路回路.280伏直流_+高频开启5-10KV 2MHz高频气体流通 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.增强的电能和离子能使高频弧转变成引导弧,然后从喷嘴喷出射向待加工的金属.280伏直流_+高频开启5-10KV 2M

23、Hz气体流通引导弧 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.280伏直流_+高频关闭高频关闭气体流通等离子弧当引导弧接触到金属后,将会附加并转移到金属上.载有电流的等离子气流产生能够熔化金属的热能,同时高流速的气体将熔化的金属吹掉.电流传感器 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formw

24、ithout the permission of Hypertherm,Inc.咯咯高频弧引导弧切割弧 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.提供电子提供电子产生了离子弧产生了离子弧清洁割缝清洁割缝 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission

25、 of Hypertherm,Inc.保护帽的作用在机用割炬切割时:通过提高喷嘴的使用寿命来降低运营成本使用寿命提高的同时,切割质量的稳定性也得到了改善提高了穿孔能力 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.无保护帽引发的问题双弧双弧在穿孔过程中由于熔化溅起的金属颗粒,使铁板和喷嘴之间导通而产生双弧,严重地损坏了喷嘴的喷口.Copyright,2003 Hypertherm,Inc.These ma

26、terials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.保护部分保护部分 使用带绝缘能力的保护帽对喷嘴进行保护,在很大程度上减少了双弧的发生率,延长了易损件的寿命.可以贴在金属板材上,依据模板进行拖拉切割 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.带保护帽的优点 减小喷嘴损坏的概率在穿孔的过程中熔

27、化的金属接触到的是铁板和绝缘的保护帽,所以喷嘴得到保护.正常l椭圆 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.单气体单气体 单一气体输入(通常是压缩空气)最大电流为100A 相同的气体用于切割,保护和冷却 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permissio

28、n of Hypertherm,Inc.双气体双气体 双重输入气体 电源能量50A-400A 使用气体或水进行冷却 因为增加了冷却,喷嘴的使用寿命得到了提高 薄板切割的变形现象得到了改善 干式等离子与水射流相比,溶渣少,光洁度高 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.双气体双气体 可以根据不同的加工材料来选择气体,可以有效地控制板材切割后的金属化学反应 切割速度快于传统的空气切割工艺 保护气可以有

29、效地降低飞射弧损坏喷嘴 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.水射流水射流(HT4001)(HT4001)水对经内喷嘴压缩后的等离子弧进行2次辅助压缩 水工作方法:涡流式/发散式 等离子切割弧密度高,速度快 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permis

30、sion of Hypertherm,Inc.水射流水射流(HT4001)(HT4001)易损件的寿命得到提高 碳钢切割范围6MM-30MM 不锈钢和铝材的切割范围75MM Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.高密度高密度(高精度等离子高精度等离子)等离子弧密度高,流速快,流量低 切割后的工件:公差范围好 割缝窄 切割面质量高 溶渣少 薄板的垂直度得到了提高 Copyright,2003 Hyp

31、ertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.空气空气 传统等离子切割工艺中最常用的气体 空气中的氧气成份,使熔化后的金属在热释放过程中产生了额外的能量 与传统的切割工艺(火焰切割)相比切割速度快 切割不锈钢或铝的材料,切割面有较明显的氧化部分 普通等离子切割工艺 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the

32、 permission of Hypertherm,Inc.氮气氮气 多数使用此气体切割有色金属 与空气,氧气作为等离子气相比,电极的使用寿命有很大的提高 在切割碳钢时,如果使用氮气作为等离子气,会产生较多的溶渣,在切割后的金属边缘就会氮化并且变硬 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.氧气氧气 在碳钢切割时,可以在低电流的情况下,就可以实现高速度切割 切割面的金属热影响区域小 切割溶渣少 切割倾

33、角小 上切割面顶部圆角小 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.氧气长寿命技术氧气长寿命技术 海别得的专利技术 通过对气体和电流的在切割开始和结束时的同步处理,解决了前期氧气等离子设备在切割过程中易损件寿命短的问题.此技术必须在切割板材上起弧,断弧.Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any f

34、ormwithout the permission of Hypertherm,Inc.目的目的:向弧提供稳定的直流电DC to power the arc.原理原理:稳定的直流输出,交流到直流的互换系统组成组成:主接触器电源变压器斩波器(整理器和 IGBT)Inductor互感器Load负载 Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.Copyright,2003 Hypertherm,Inc.These materials cannot be reproduced in any formwithout the permission of Hypertherm,Inc.